Downloaded from http://www.everyspec.

com

ZE.!mml

MIL-W-1687BF(NAVY)
SUPERSEDING
MIL-W-16878E(NAVY)
10 August 1?51
(See 6.9)

MILITARY SPECIFICATION
WmE, ELECTSUCAL, IimmAmD,
GENERA.LSPECIFICATION FOR

This specification is approved for use by the Deparmnt of tha Navy and
is available for use by all Deparusents and Agencies of the Department
of Defense.
1. SCOPE
1.1 ~.
This specification covers unshielded wire for hookup and lead
size
wiring of electrical and lectronic components and quipment so that nik
and weight are consistent with service requirements. The testpermure rating of
of 260 degrees Celsius
wire included in this specification ranges to a ~
(C), with potential rating from 250 to 5000 volts root meen square (Vrms).

1#

1.2 ~.
Wire is of the following conductor naterial, sizm,
stranding,and insulation color code, as specified (s-e 3.1 and 6.2).
1-2.1 ~.
as specified (see 6.2.1):
K16B7am
(see 1.2.2)

B
(see

Part numberbs shall be of the following form,

1.2.3) (see 1.2.4)

(see 1.2.5) (see 1.2.6)

The Military specification sheet

1.2.2 ~.
number designation consists of a prefix H which indicates a military specification
item, the specification number and the specification sheet number.

Beneficial coawents (recmndations,

dditions, del*tions) and any pertinent
daeauhich muybeof ueeiniqmovhg
this ~t
should be 8dd~8SS8d to:
@mender, lhmal Sea Systems Comend, SBA 5S23, Department of the Navy,
Washington, DC 20362-5101 by using the self-addressed Standardization ~t
Improvement Proposal (DD Form 1426) appearing t the nd of this document OK
by letter.

A#!sCN/A
~.
L

Approved f=

FSC 6145
PUbl~C rel-se; distrib~~on iS Unlimited.

Downloaded from http://www.everyspec.com

CGRdU~~QY Fa:fTTq~. Corcdu~~orma~eri~] jg as Specitis!d ISE~~ 1!,

with tneconductor material designated by a single letter specified as foiiows:
:..3

Coated copper.
C - Coated copper-clad steel (C.C. Steel).
B-

EE=

Coated high-strength co~per alloy !F5.C A.}.

Coated copper with overall metallic coating.

1.2.h Conductor size. The conductors American Wire Ga~e (AWG) size is
designatedby a sin~le letter specified as follows:
4?KZ6&LexkMLSLL4kK
32
30
28
26
24
22

A
B
c
D
t
F

20
18
16
14
12
10

M?GLELQ2XS=
G
M
J
K
L
n

8
6
h
2
1
o

N
P
R
s
T
u

w
Y
2

00
000
0000

AWG for solid conductor is standard AUC; stranded+wire %s to the cloaemt evennumbered AUG with normal stranding (7, 19, 37, and so forth) (see 6.1.2).
1.2.5
. The number of strands making up the conductor is
designatedby a letter specified as follows:
titter
1
7
10
16
19
26
37
41
65
105

A
B
c
D
E
F
G
H
J
K

133
168
259
665
817
1045
1330
1672
2109

L
n
~
P
R
s
T
v
u

1.2.6
on color c d
The tneulation color code %s in accordance
with the identification codings;stem of KXL-STD-681, and may ba 1, 2, or 3 digits
depending on the number or absence of strips or bands. The first rnnsboris *
color of tlm insulation, the second number represents the color of the first stxiP .
of
cm band, the third nuaber, the color of the second strip or band. ksiption
the color code need net be imprinted on the wire. The colors nd their
correspondingnumber are as follows:

Downloaded from http://www.everyspec.com

COLOR
CODF CPA!!T
....+.
Number

Number
Qesimat o r

Coloc

o
1
2
3
&

Black
Brown
Red
Orange
Yellow

Colm

Green
Blue
Violet (purple)
Gray (slate)
White

5
6
7
8
9

The colors listed are the preferred colors in ccordance with FED-STD-595 unless
the contracting ctivity specifies alternates (see 6.2).
2. APPLICABLE
~
.
2.1 ~t

d-nt~

The following specifi2.1.1 ~~ec=cari~s.

sta@@s.
and handbooa.
cations, standards, and handbooks form a part of this document to the extant
specified herein. Unless otherwise specified, the issues of theme documents re
those listed in the issue of the Departmentof Defense Index of Spaoificstionsand
Standards (DODISS) and supplement thereto, cited in the solicitation (see 6.2).
SPECIFICATIONS
FEDERAL
QQ-S-571
ZZ-R-765
PPP-F-320

- Solder, Tin Allby: Tin-Laad Alloy; and Lead Alloy.

- Rubber, Silicone (General Specification).
- Fiberboard: Corrugate&and Solid, Sheet Stock
(Oontainer Grade), and Cut Shapes.

MILITARY
?HL.C-S72

- Cords, Yarns and Monofllaments Organic Synthetic

Fiber.
IULE-917
- Electrical Power Equipment; Basic Requirements
(Naval Shipboard Use).
HIL-Y-1140 - Yarn. Cord. SleevinE. Cloth, and Tape-Glass.
KIL-C-12000 - cable, Cord, and Wi~e, Elactric; .Pa&aging of.
?IIL-L-19160- Ltmber and Plyuood, Fire-Retardant Treated.

STANDARDS
FEDERAL
FED=STD-228 - Cable and Wire, Insulated: Methods of Testing.
FED-STD-595 - Colors Used in Governmcm Procurement.
MILITARY
HXL-STD-104 - Limits for Electrical Insulation Color.
MXL-STD-105 - Sampling Procedures and Tables for Inspection by
Attributes.
NIL-sTr)-45L- Standard General Requirements for Electronic
%luipment.
9
,,

Downloaded from http://www.everyspec.com

!.!L-L
.lf)8!:~!iAVl;l;

(Unless othexwise indicated, copies of federal and milita~ specifications,

standards. and hanobooks are available from ~he Scaridardization Documents Ordc=
Desk, BLDG. 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094.)

2.2 ~on-Government mlblications. The following document(s) form a part of

this document to the extent specified herein. Unless oche-ise specified, the
issues of the documents whjch are DOD adopted are those listed in the issue of the
DODISS cited in the solicitation. Unless otherwise specified, the tssues of
documents not listed in the DODISS are the issues of the documents cited in the
solicitation (see 6.2).
,AMEMCAN NATIONAL STANDARDS INSTIIWTE (ANSI)
B46.1 - Surface Texture {Surface Roughness, Waviness, and Lay).
(DoD adopted)
(Applicationfor copies should be addressed co the American National
Standards Institute, 1430 Broadway, New York, NY 10018.)
AHERICAN SOCIETY FOR TESTING AND HATEUIAXS {ASTM)
B33
- Standard Specification for Tinned Soft or Anw+led Copper
Wire for Electrical Purposes. (DoD adopted)
B 173 - Standard Specification for Rope-Lay-StrandedCopper
Conductors Having Concentric-StrandedMembers, for
Electrical Conductors. (DoD adopted)
B 286 - Standard Specification for Copper Conductors for Use in
Hookup wire for Electronic Equipment. (DoDidoptedl
B 298 - Standard Specification for Silver-Goated Soft or Annealed
Copper Wire. (DoD adopted)
B 355 - Standard Specification for Nickel-Coated Soft or Annealed
Copper Wire. (DoD adopted)
B 670 - Standard Specification for Bonded Copper Conductors for
Use in Hookup Wire for Electronic Equipment.
B 501 - Standard Specification for Silver-Coated, Copper-Clad
Steal Wire for Electronic Application.
B 559 - Standard Specification for Nickel-Coated, Copper-Clad
Steel Vire for Electronic Application.
B 624 - Standard Specification for H@h-Strmgth, HighConductivity Copper-AlloyWire for Electronic
Appllcatlon. (DoD adopted)
D 1248 - Standard Specification for Polyethylene Plastics Molding .
and Extrusion Materials. (DoD adopted)
D 2116 - Standard Specification for FEP-Plwwcarbon !40Ming nd
Exmxsion Materials. (DoD adopted)
D 4066 - Standard Specification for Nylon Injection and Extrusion
Materials (PA). (DoD adopted)
I)4314 - Standard Specification for General-Purpose, Heaw-Duty.
and Extra-Heavy-Duty Crosslinked Chlorosulfonated
Polyethylene Jackets for Wire and Cable.
D4895 - Standard Specification for Poly!xtrafluoroethylene (PTFE)
::esinProduced from Dispersion.

Downloaded from http://www.everyspec.com

G2L.

Standard Practice ior Determining Resistance of Synthetic

Polymeric Materials

to Fungi.

(DoD adopted)

(Application for copies should be addressed to the American Society for

Tes:ing md tl~terials, 1?16 .R=e Strec:, ?hiladelphie, ?A ~0103.)

NATIONAL ELECTRICALMANUFACTURERS ASSOCIATION (NEMA)

UC 52 - High-Temperature and Electronic Insulated Wire-Impulse
Dielectric Testing.
(Applicationfor copies should be addressed to the National Electrical
Manufacturers Association,
Suite 300, 2101 L Street, NW, Washington, DC 20037.)
SOCIETY OF AUTO!40TIVEENGINEERS, INC. (SAE)
MS 3249 - Ethylene Propylene (kPD?l)Rubber Hydrasine-Base-Fluid
Resistant 75-85. (DoD dopted)
(Applicationfor copies should be addressed to Society of Automotive
Engineers, Inc., LOO Commonwealth Drive, Warrendale, PA 15096.)
UNDERWRITERS LABORATORIES, INC. (UL)
1581 - Reference Standard for Electrical Wires, Cables and Flexible
Cords.
(Applicationfor copies should be addressed to Undarwricerslaboratories
Inc., 333 Pfingsten Road, Norchbrook, IL 60062.)

INc.
INsuLATm CASLE ENGINEEM AssocwrIoN,
Publication T-24-380 - Partial
Discharge Test Procedure
(Applicationfor copies should be ddressed to Insulated
$woc%ation, Post Office BOX 440, South Yarmouth, MA 026M.)

Cable Engineers

(Non-Goverrnsent
standards and other publications are noraally available from
the organizations-t
prepare or distribute tb documents. These documents also
s*ndw.)
may be available in or through Libraries oz other informational
In the event of a conflict between the text of
2.3 ~.
this doctment and the references cited herein (axcapt for rc~ted associated
speclfloationsheets), the text of this doament takes precedence. Nothing h
this document, however, supersedes applicable laws and repd.ations unless a
specific exemption has been obtained.

3.1
. The individual item requirements shall be as
specified here$n.and in ccordance with the pplicable specification sheet. In
the event of sny conflict be~een We requirements of this specification and the
specificationsheet, the latter shall govern.

Downloaded from http://www.everyspec.com

~,~

~]assific~tj~~ Of y~c,~j,~emen~s
, The applicable requirements are
classified as follows:

First article
Materials
Construction
Performance

3.3
3.4
3.5
3.6

3.3 First article. When specified (see 6.2), a sample shall be subjected to
first article inspection (see 6.3) fn accordance with 4.3.
3.& Hateri~.
Materials shall be as specified herein. When a mattrial is
not specified, a material shall be used which will enable the insulated wire to
meet the performance requirementsof this specification. Acceptance of any
constituentmaterial shall not be construed as a guaranty of the acceptance of the
finished product (see 4.5.1).
3.4.1 $onductor~. Conductors shall be solid (see 6.1:3) or stranded as
specified in table I, or s pproved by the contracting
act%vity. Each SUad of
the conductor shall be of the same composition. When coated wires are uwd,
individualstrands shall be coated before stranding. Each strand shall have the
same coating. Application of metallic coating shall be permitted after stranding
in accordance with ASTM B 470, type 11. Conductors shall meet the requirements
specified in 3.4.1.1 through 3.4.1.7 before application of insulation.

r c~
. Tin-coatsd copper conductors shall
be in accordance with MIX B 33 for soft, annealed copper.
3.4.1.2 ~ver-coated. c~.
copper conductors shall be in ccordance
(minimum)thickness of silver.

Silver-coated, soft, annealed

with ASTM B 298 with 40 nicroi.xdw

3.4.1.3 pi kel .coated- c m~ctors

Nickel-coated, soft. ~aied
copper conductor: shall be in ~ccordance with ~TM B 355 and shall be coated with
50 microinches (minimum) thickness of commercially pure nickel.
Sllvcr-coatod,
3.4.1.4 $il er -coat d. cobwr-c~a d . steel co*m
copper-clad steelvconduct~rsshall be in ccordance with ciass 40A of AS%N B 501
with 40 microinches (minimum)thickness of silver.
Nickel-coated,
3.4.1.5
el .coated.
copper-clad steel conductors shall be in accordance ~itb A!& B 559 with 50
microinches (minimnm) thicjness of coameercialnickel.
3.A.1.6 ~-stre~.
cower ~lov eo@xto~
. Mgh-strmgth, copper lloy
conductors shall be in accordancewith ASTM B 624 and table I. The strands shall
be silver- or nickel-coated in accordance with 3.4.1.2 or 3.4.1.3 as applicable.

Downloaded from http://www.everyspec.com

.. .
I

.A

/-

. ..

.-i m.+ [)-J

-4

,:,
.

.-6

.2

(X

.-

,-4

o
&

G
9
0

Cu

.-.

?J$
=.A

6.---.

3 . . ...

..

. . - . . ...

00000009000

!-4

0000000000000

. ..

Downloaded from http://www.everyspec.com

.
k

.-

au-mfl-$ddddd

00000000000

..

Ooooooomomo

8)

Q
c
*

__...

-_. ----

Downloaded from http://www.everyspec.com

m
a

s-l
a

u
o

0
r5

0-4

Downloaded from http://www.everyspec.com

NIL-K- 1fJ878F<>~lPJ:l

?.4 .1.7 Coared cower with overail metallic ~oati~Coated coPPer

conductors in which wires in the scran~ are metallically bordad together by the
application of overall tin or alloy coating. Coating prevents strand fraying and
shall be in accordance with ASTM B h70, Type 11
?laterialsshall be as specified in
3,L.2.1 through 3.4.2.8 as applicable (see 3.1).
3.6,2

Insulation and iacket nacerti.

3.&.2.l PolWinvl chloride (PVCI. When specified (see 3.1), the insulation
shall be PVC or its copolymer polyinyl acetate, vhichconforms to the requirements
of the applicable specificationsheet.
3.4.2.2 Eolvamide (nvlonl. When specified (see 3.1), polyamide shall be in
accordance with ASTM D 4066 or when used in braid shall be in accordance with type
P of MIL-c-572.
3.4.2.3 Fluorinated etiwlcn mroutine
shall be in accordance with ASTM ; 2116.
3.4.2.k X ~Yt trafluoroethvlene {~
shall be in cc~rda~ce With ASTM D 4895.

(m

. b%en specified (see 3.1), FEP

. Uhen specified (see 3.1), PTPE

3.4.2.5 Polvethvlenq. When specified (see 3.1), polyethylene shall be in

accordance with type 11 of ASTM D 1248, except colored material can be used.
When spacified (see 3.1), silicone rubber shall be
3.4.2.6 ~.
in accordance with class 2a, grade 25, 40, or 50 of ZZ-R-765.
3.4.2.7 Chlor sulfon ted vol~ne
=
CSPE shall be in ac~ordancs with ASTM D 4314.
3.4.2.8 5thv~-moDvlene
die~sr~
3.1), EPDH shall be in accordance with SAEAMS

When specified (see 3.1),

When specified (see
3249.

3.4.2.9
d material. Additional materials shall be acceptablefor
changing the above materials if the crosslhked final product meets the
requirements of the pplicable Specification sheet (see 3.1).
3.4.2.10 Other mat-.
When other materials are specified,theyshall be
certified virgin materials containbg no additives,
except those required ss
wetting agents, pigmentations for color, and lubricants wed in ext~ion.
3.4.3 ~.
When speclfled (see 3.1), braids shall be synthetic textile in accordance with type P of ML-C-572, or glass yarn in accordance with MXL-Y-1140,
as specified (see 6.2).
3.5

Cons~tion.

3.5.1 Conductors. Stranding shall be as specified in table I after

insulation. The conductors shall be round in shape, uniform in cross seccion and
free from flaws, scales and other imperfection.s. Unless ozhelwise specified (see
6.2]. the method of stranding for AUG sizes No. 32 (single cmduccor) through No. ~

Downloaded from http://www.everyspec.com

!41L-b-l6878F+/uAvy)

10 (105 stranding) inclwive, shall be at the option of the contractor. Rope lay
stranding only shall be used for AUG sizes No. 8 (133 strandzng) and Larger.
Length of lay of finished, stranded conductors shall be in accordance with ASTM B
286 or ASTM B 173, as applicable.
3.5.2 Jnsulation, A tight-fitting, continuous coating of insulation shall
be added over the conductor and shall be cured, processed, or maintained to
provide for accurate centering of the conductor (see 3.6.6). The insulation shall
be free from splinters, blisters nd other non-homogeneities visible to the normal
eye. The insulation shall be constructed to be readily stripped from the
conductor
co that
the conductor is clean for soldering or crimping. A clean
conductor shall have no particles of insulation visible to the naked qe.
3.5.3 ~.
When specified (see 3.1), a closely voven braid shall be
applied over the insulation. Braids shall be saturated or filled and coated with
fungus-, heat-, flame- and moisrure-resistant lacquers to a smooth finish which
shall minimize fraying at the cut en& under conditions incident to handling while
being installed and during normal sexvice.
Coatings shall be sufficiently
translucentso as not to impair the visibility of any underlying color code of the
braid materials when strips are specified. Color carriers used in braM.s shall be
one carrier
(minimas) revolting in the same direction and shall be composed of
synthetic textile or glass yarn (see 3.4.3). The braid shall not increase the
outsi& diameter of the finished wire by more then the maximum amount specified in
table II.

Diameter over insulation

(inch)

.
3.5.& &ckeq.
insulation.

0.125 or less
0.126 - 0.250
Greater than 0.250

Diameter f.morease
(inch, maximum)
0.015
0.020
0.03s

When specified (see 3.1), a jacket shall be extruded over the

3.5.s ~.

colors shall be in accordeaoe withmI.L-sTD-M4; class 1,

wham oroealimkiag is dome by irradiation.
When Insulation surfaces have bean oolor ooded wi~ laks or dyes; they shall be
nonconductive, permanently fast and shall not change, fade, rum, or blead WIMn
used in direct sunlight and within the specific temperature rating of the
insulationmaed.

xcept pastel colors shall be coep~le

When specified (see 3.1), the length of lay of

3.5*5.1 ~.
colored stripes shall be as specified in table XII.

Downloaded from http://www.everyspec.com

TABLE 111,

Lenzth of lay of

Diameter over finished wire

S trin~.

bngth

of lay

(inch)

(inches, maximum)

0.000 CO 0.083
0.084 to 0.110
0.111 and larger

1.00
1.50
2.00

3.5.6 $Dlices. Splices shall not be ma& in a szrxnded conductor as a whole;

however, individual strands and solid conductors may be spliced. Splices shall be
made by electro welding or brazing with silver composition solder in accordance
with QQ-S-S71.
3.6 perfo~
e. Unless otherwise specified herein, all requirements (see
3.6.1 through 3.6.16) shall be met on finished wire.
,
3.6.1 ~ulation
flaw~. After application of the primary insulation, the
wire shall withstand the spaxk test or Impuse dielectric test voltage as
specified (see 3.1) without breakdown. Afzer applications of braids or Jackacs,
the finished wire shall withstand the spark test or the impulse dielectric test
without breakdown <see 4.5.2.1 and 4.5.2.2).
3.6.2
The wire shall withstand the
specifiedvoltago for 1 minute (mixdua) wi&iout breakdown (see 3.1 and 4.S.3).
3.6.3
. The insulation resistance shall be not less
than the value ~pecified (see 3.1 and 4.5.4).
The conductor resistance of the finished wire
3.6.h ~.
shall be not greater then the value specified (see 3.4.1 and 4.5.5).
3.6.5 ~oldben~.
Specimensshall reveal no readily visible cracks in the
voltage
requirements as
insulation nd shall pass the dielectric withstanding
specified (sm 3.6.2 and 4.5.6}.
3.6.6 Conc~.
The concentricity of finfshedwlre insulationend the
primary i.asulationof dtl-leyered Lneulation or jacket, SW
be 70 percent
(minimum). The faflure of the concentricf~ of any cross-section shall constitute
failure for the entire speciaen (see 4.5.7).
3.6.7
. The surface
(w%re ti~
res~s~e
shall be 5 Dsgoba-i.xIches
(minimum). A surface resistance of 1SSS ~
1000 megohm-inches shell not change by mora then SO percent from the inicf.al
measured value after the application of the high potential end remeasurementOf
surface resistance (see 3.1 and 4.5.8).
Specimens shall reveal no
3.6.8 Urariback test (nFE insulation
cracks when visually examined and shall pass the dielectric withstanding voltage
requirements as specified (see 3.6.2 and A.5.9).

12

.. .

Downloaded from http://www.everyspec.com

MIL-U-16878F{NAVY)

3.6.9 Heat resist nnce. Specimens shall reveal no cracking or delamination

of the insulation (and jacket when applicable), no ex*tion of we i~~tion
through the braid in constructions incorporating braids, no readily visible
defects in any of the wire component parts (slight discoloration after aging is
considered normal nd acceptile) and shall pass the dielectric viths-ing
voltage requirements ES specified (see 3.6.2 and 4.5.10).
.
3.6.10 -ablJJ@.
Insulation shall not burn for more than the specified
time and the flame shall not travel more than the specified distance nor release
flaming particles that ignite combustible materials in its vicinity (see 3.1 and
4.5.11).

3.6.11 SihKhMQ.
Insulation shall not flare away from the conductor nor
open up over the bent portion, nor shrink back more tha.nO.125 inch (see 4.5.12).
Insulation elongation and tensile strength shall not
3.6.12 ~.
change more than specified (see 3.1 and 6.5.13).
lation tensile strene*
3.6.13
ihe minimum tensile screngtb of
insulation shallbe as specified (see 3.1 and 4.5.14).
3.6.14 ~.
as specified (see 3.1 and 4.5.15).

fie~*uIse

longationof

insulation shall be

3.6.15 ~.
AiIIi~
Of 125 cycles f he
mandrel shall not remove the printed marking or color code stripe from the wire
s~le
(see 4.5.16).
All nonmetallic materials, including compounded
3.6.16 ~.
materials, that are not fungus-inert in ccordance with MIL-STD-&54 shall bS
fungus resistantas specified (see 3.1 and 4.5.17).
3.6.17
ulati~
tl~
ext~d
The circumferentialelongation for m
the average percent for conductor size of y~le
T=~.

extruded ~on
O- .
shall not be less than
IV (sea 4.4.3.1.3
and 4.5.19).
(PTFE

insuhtim

Conductor size

Percent (Average)

28 to 16
14 to 12
10 to 8

200
1.50
100

Test shall be ma& prior to the c and dc

3.6-1; ~.
voltage tests on the lead wire. The applied voltage shall be raised to value
equal to.20 percent greater than the minimum partial-discharge extinction levnl
This test
but shall not exceed the required ac test voltage for the lead wire.
shall be as specified in 4.5.20,

13

Downloaded from http://www.everyspec.com

MTL-U-lb87f?.
F<NAVk)

3.7 Jdentifjcation of mroduc~. Unless otherwise specified {SW 3.1 and 6.2),
finished wire shall be identified by a printed marking applied to the outer
the
outer
surface. The printed
surface of the wire or visible through
identificationshall be at intenals of 9 to 60 inches oeasured from the beginning
of ~ne =oq~ete ~ark~ng to the ~eg~nn~ng of the succeeding complere marking and
shall consist of the following:
(a) K16878/* (* applicable specification sheet).
(b) Conductor material as identified per PIN number.
(c)
Conductor size as Identified per PIN number.
(d) Voltage rating
(e) Manufacturers supply code designation.
Printing shall be of a contrasting color (black or white is preferable) in a
permanent ink or dye. Idencificacionprinting shall be applied with the vertical
axis of che prinC8d characters either crosswise or lengchwlse on the wire when the
nominal diameter of che wire is greater than 0.050 inch. Identificationprinting
shall be applied with the vertical axis of the printed characters lengthwise on
the wire when the nominal dismecer of the finished wire is 0.050 inch or smaller.
Printed characters shall be complete and legible to the naked eye.
3.8 Uorkmanshi~. Wire shall be free of kinks, abrasions, and cracked or
peeled surfaces. Wire shall be a uniform and consistent product and shall be free
from defects which will adversely affect the serviceability of the product.
3.9

~.

Materiala specified herein for the construction of the

insulatedwire shall be selected to provide maximum resistance to burning. The

combustion of these materials shall not create concentration of toxic gases that
exceed maximum concentration levels specified in HIL-E-917, table I (see 3.6.10,
4.5.11 end 4.5.18).
Uith respect to toxici~

levels of wire inspected to this specification, it SS the

Goverments intent to accumulate data from the testing of first article samples.
This data will be compiled and evaluated to establish ppropriate concentration
levels of toxic gases for future acceptable maximum concentration levels.
Contractors are requested to provide such data with repect to their products
following first rticle testing. This date will noc be used for the rejectionof
~
prkct
first article testing.
4.

wm--=-=~sx~s

Unless otherwise specified in the

4-1 ~.
contract or purchase order, the contractor is responsible for the performance of
ll inspection requirements (examinations nd tests) as specified herein. Except

es othertrlsespecified in the contract or purchase order, the contractor BSY use

hls own ox ny other faciliths suitable for the performance of the inspection
requirements specified herein, unless disapproved by the Government. The
to perform
any of the inspections set forth in this
Gove~ent
resezwes the right
specification where such inspections are deemed necessary to ensure supplies and
scmices cmfom
cc prescribed requirements.
.

Downloaded from http://www.everyspec.com

IlIL-W-16878HNAVS)

~esnonsfhilftv for comolJ.

4,1.1
ante. All items shsll meat all requirements
of sections 3 and 5. Xhe
inspection set forth in this specification shall become
a part of the contractors overall inspection system or quality program. The
absence of any inspection requirements in ~e specification shall not relieve the
contractor of the responsibility of ensuring that all products or supplies
of the
submitted to the Government for acceptance comply with all require-n~
contract. Sampling inspection, as part of the manufacturing operations, is an
acceptable practice to ascertain conformance to requirements, however, this does
not authorize submission of known defective material, either indicated or actual,
nor does it conseitthe Government to ccept defective oateri.al.
4.2
Classification of inspections. The inspection requirements specifisd
herein are classified as follows:

(s) First rticle inspection (see 4.3).

(b) Quality conformance inspection (see 4.4).
First article inspection shll co~ist of all
4.3
~.
the tests (groups A, B, and C of table V) and examinations of this specification.
inspection shall
Quality Confozma=t
4.4 ~.
consis~of the inspections Msted in table V (groups A and B) and as specified in
4.5. Quality conformance shall be performed on every lot of wire procured under
this specification.
4.4.1 ~.
Unless ofierwise specified (see 6.2), an inspection
lot shall consist of ll wire of the same part number, produced under essentially
the same conditions, and presented for.inspection and shfpment t one time.
4.4.2
of vro~
. The unit of product for determining lot size .for
Wt
sampling shall be the quantity of wire offered for inspection on one coil, O*
reel, or one spool, s applicable.

Group A inspection shall consist of the tests

4.4.3
~.
specified in table V. These tests cannot be performed on the finished wire s
submitted for Inspection; therefore, they shall be performed t the most
appropria~ stage of th~ manufacturing operation. The tests shell be performed on
every lot of wtre acquired under this specification.
.

. ,-,

--------

... . .. . .

. .

4.4.3.1 <.
Sampling for grk~ Ainepectian shellb~:aa specified in
4.4.3.1.1 and 4.4.3.1.2.
4.4.3.1.1
(extent f~
Three
al examina~
nd
samples representative of the inspection lot shall be selected (see 6.6.1.1).
Wire provided under this specification shall be
4.4.3.1=2
~.
subjected to the appropriate insulation flaws test as specified in 4.S.2.
Insulation breakdowns resulting from this test and ends or portions net subjected
to the test, shall bc cmked or cut out of the finished wire.

Downloaded from http://www.everyspec.com

ML-u- i6876F4NAW)

.cion oniyl. .Wire

.
Circumfe rential elon~ ation [extxuded ~FEJJISUL@
insulationshall be sub~ected to the circumferential elongation test as spec~fled

4.4.3 .1.3

in fb.5.19.
. Croup B inspaczion shall consist of the tests
that have

&.J+.& ~rouD B
specified in table V.

The sample shall be selected from inspection low

passed group A inspection.

L.fb.f).l
M ecimens. Smples for group B inspection shall be 26 foot
(minim~] lengths for the insulation resistance test. and unless othenfise
specified herein, for all other test shall be the length specified in rhe
applicable test method. Only one specimen for each test shall be taken from any
one sample unit.

TABLE

V.

First

r cicIs$
fI

anda~w

~i

Requirement

Inspection

ons.

Test Method

Group A
Visual nd mechanical

examination
Insulation flaws:
Spark
Impulse dielectric
Circumferentialelongation

3.1, 3.4, 3.4.1, 3.5.

3.5.6, 3.7 and3.8
.
3.6.1
3.6.1
3.6.17

4.5.1

4.5.2
4.5.2.1
4.5.2.2
4.5.19

Group B
Dielectricwiths-~ng
voltage
Insulation resistance
Conductor resistance
Cold bend
Concentricity
wrap back
Insulation tensile strength
Insulation elongation
liarkingand stripe durabili~

3.6.2

4.5.3

3.6.3
3.6.4
3.6.5
3.6.6
3.6.8
3.6.13
3.6.14
3.6.15

4.5.4
6.5.5
4.5.6
&.5.7
4.5.9
4.5.14
f4.5.15
4.5.16

Group C
Surfaoe

resistxbce

Hut r8si8tamce
Fleusaabili~
Shrinkage
Heat ging
Fungus resistance
Toxicity

3.6.7
3.6.9 ;..
3.6.10
3.6.11
3.6.12
3.6.16
3.9

ih

4.5.4~
4.5.10
4.5.11
4.5.12
4.5.13
4.5.17
4.S.18

Downloaded from http://www.everyspec.com

MIL-X-16878F<NAW)

TABLE 1 First artjc~e amd qu~l; tl, conformance immections.

Inspection

Test method

Requirement
I

Classification
of defect

Group A

Visual and mechanical

examination

3.1, 3.4, 3.4.1,

3.5, 3.5.6, 3.7
and 3.8

L.5.1
4.5.2

tlaj
or

3.6.1
3.6.1

&.5.2.l
4.5,2.2

Critical
Critical

3.6.17

4.5.19

Hajor

3.6.2
3.6.3
3.6.4
3.6.5
3.6.6
3.6.8

4.5.3
&,s.fb
4.5.5
4.5.6
4.5.7
4,5.9

critical
Kajor
Major
Hajox
Critical
Critical

3.6.3.3
3.6.14

4.5.14

Critical
Critical

Insulation flaws:

Spark
Impulse dielectric
Circumferential
elongation
Group B
Dielectric
withstanding voltage
Insulation resistance
Conductor resistance
Cold bend
Concentricity
Urap back
lnaulation tensile
strength
Insulation elongation
Marking and strip
durabili~

4.5.15

3.6.15

4.5.16

Minor

3.6.7
3.6.9
3.6.10
3.6.11
3.6.12
3.6.16
3.9

4.5.8
4.5.10
4.5.11
4.5.12
4.5.13
4.s.17
4.5.18

nejor
Major
!linor
Uajor
Major
Minor
--Z/

Group C
Surface resistance
He&t resistance
namebiliq
Shrinkage
Heat Aging

_
~i%~e
Toxicity
L/

Crieical defect - A defect likely to result in hazardous or unsafe

conditions for-indivhhals; or is,likely to prevent
parfomsnce of tie tactical fimction of a major end
item such as an aircraft cormaunicationssystem, or
mul.npart thereof.
hjor

defect

- A defect, other than critical, likely to result In

failure
or reduce materially the usability of the
product for its intended purpose.

17

Downloaded from http://www.everyspec.com

?ll
L-W-16878 F<NA~)

Minor defect

- A defect not likly to reduce materially the usabiiitY

of the produc~ for its intended purpose. or is a

departure from established standards having little

bearing on the effective use or operation of the
produce.

A.4.4.2 $=n~inr Dla

The sampling plan shall be in accordancewith
F!IL-STD-105for special in~pection level S-2 (see 6.6.2). The sample size shall
be based on the inspectionlot size from which the sample was selected for group A
inspection.

b.4.4.3 Re~ected lots. If an inspection lot is rejected, the contractor may

rework it to correct the defects, or screen out the defective units and resubmit
for reinspection. Resubmitted lots shall be inspected using tightened inspection.
Such lots shall be separate from new lots and shall be identified as reinspected
10CS .
L.4.L.4 Disposition of sanlDle un its.
Sample units which have passed all khe
group B inspections may be delivered if the lot is accepted and the sample units
are srlll within specified electrical tolerances.
4.5 tiethods f insvectioq.
6.5.1 through 4.5.~7,

Inspections shall be performed as specified in

.
4.5.1
ex~atlon
. Finished wire shall be examined to
dete~ine that the materials, physical dimensions, constmction, splices. -rking,
and workaanahip re in accorda~e with the applicable requirements (see 3.1, 3.4.
3.4.1, 3.5, 3.5.6, 3.7, and3.8 respectively).
4.5.2 ~.
Testing for ix=ulation flaws shall be as specified
in4.5.2.l tttrough4.5.2.2, as applicable.
L.5.2.1 ~.

The spark test shall be performed in accordance with

method 6211.1 of FED-STD-228 at

to 9
of volt$ge t

rate that subjects each point on the tire

cycles (Rinimsm) of voltage at 60 hertz (~) or 12 qc19s (ninkxb)

3000 Hz. l%e tast voltage shall be as specified (see 3.1).

Tba impulse dielectric test shall be in

4.5.2.2 ~.
accordance with NEMA UC 52, except tie i~~at~~
sM1 be reaovad or Mentlfied
side of tiepoi.nt of
for subsequent removal fox a infmm of 3 inches oneacb
dielectric failure. The test voltage shell be as specified (see 3.1).
Vo~.
~
4.5.3
Om *
of ilmzlationshll be

and the specimen shall be t~cbed to an

removed from each eml of th. apec~n
electrlc lead. The specimen shall be imetsed in 5 percent (by weight) solution
of sodim chloride in water at 20 to 25*c, except the uninsulated ends, plus 1.S
inches of fnsulaced wire t each nd, shall be exposed to the air. ARer
immersion for 1 hour, the voltage specified (see 3.1) at 60 Hz shall be applied
between the conductor and an electrode in contact with the liquid. The applied
voltage shall be unifornly increas~d from zero to the specified peak voltage in 30
seconds, maintained at that voltage for a period of 1 minute and uniformly reduced-.,
18

Downloaded from http://www.everyspec.com

KIL-G-Ma7t.F{liAvYj

>.

to

zero

in 30 secon&.

Wire shall meet the requirements specified in 3.6,2.

The insulation resistance test shall be

4.5.4 ~.
performed on the same wire sample used for the Dielectric Withstand Voltage Test
the
(4.5.3)and shall be in accordance with method 6031 of FED-STD-228 vith
following exceptions:
(a) The test voltage shall be 500 +/- 5 volts direct current (Vdc)
applied for 60, plus 5, minus O seconds from the time it is
reached.
(b) The specimen shall be at least 26 feet long.
(c) The stf.rrerneed not be used.
Wire shall meet the
. requirements specified in 3.6.3,
4.5.5 Conductor re~
The conductor resistance test shall be
performed in accordance with method 6021.1 of FED-sTD-228. Wire shall meet the
requirementsspecified in 3.6.&.
4.5.6 gold be@.
The cold bend test shall be performed in accordance with
method 2011 of FED-STD-228 with the following exceptions:
Specimen length shall be 12 inches, plus length required for
wrapping on the mandrel.
(b) Specimen shall be stripped 1 inch on each end down to the bare
conductor,
(c)
Usmdrel size shall be as spec%f%ed (see 3.1).
(d) Mandrels of less than 3-inch diameter shall rotate t rate of
1S +/- 3 revolutions per minute (4.0 +/- 0.2 seconds per
revolution).
(e)
Specimens shall be conditioned as specified (see 3.1).
mandrel is specified shall
(f) Specimens for which a 3-inch or larger
be subjected to a 180-degree bend over the mandrel, Chen -o-d
and bent 180 degrees in the opposite direction over the mandrel.
Specimens for which a mandrel less than 3 inches in diameter is
specified shall be subjected to at least three close turns of wire
on the mandrel and rewrapped in the opposite direction in a
(a)

similar msmrum.
The specimen shall

be removed from the mandrel and e~inadwithout

straightening.
(h) Wire shall be ilwaersed,except for 1.5 inches on ach end, for 1
hour at 30*C (maximum).
(i) After 1 hour, while ieeaersed,wire shall be subjected to the
dielectric withstandi.ngvoltage test specified in 4.5.3.

(g)

Wire shall meet the requirements specified in 3.6.S.

The concentricig of the insulation shall be messtied
4*5.7 ~.
on a cross-sectionof the finished wire at 10X magnification. If the vire
construction includes additional layers over the primary insulation, separate
determinations shall be made tor the primary insulation and finished wire. In
making the determination, the minimum thickness of the primary insulation or

Downloaded from http://www.everyspec.com

finished wire shall be located and measured in the cross-section. The maximum
thickness of the pri=ry insulacior, or finished bi~e wall shali be located ana
measured in the same cross-section. The percent concentricity is 100 times the
ratio of the mi*
measurement to the corresponding maximum measurement. Three
cross-seccions shall be measured in each specimen. Wire shall meet the
requirements specified in 3.6.6. The failure of the concentricity of any crosssection shall comtitute failure of the entire specimen.

h.5.8
. Surface resistance
shall be measured in accordance with method 6041 of FED-STD-228 with the following
exceptiom- and additio=:
(a) Two 0.250 inch electrodes consisting of ring-type metal foil shall
be allowed.
(b) Electrodes shall be attached near che center of the specimen
(c)

length.
The maximus potential shall be 200 to 500 Vclc.

(d) Specimen shall be conditioned at 25 +/- 5-C, and 95 percent

relative humidity.
(e) If the initial surface resistance is greater than 1000 megotusinches, the test shall be considered complete.
Wire shall meet the requirements specified in 3.6.7.
4.5.9
Ura~ back test (mm
insulation onlv~. The center portion of a 12inch (minimum) length specimen of finished wire shall be t@htly wound back on

i.ts*lffor a minimum of four close turns (see figure 1). The specimen shall then
be placed in an oven and heated for 2 hours at 307 +/- 5C. At the end of this
period, the specimen shall be examined (without magnification) nd subjacted to
the dielectric withstanding voltage-test specified in 4.5.3. Wire shall meet the
requirements specified in 3.6.8.

.-.

MCURE

1.

UraD back tes~.

4.5.10 Heat resistancq. Specimens of finished wire shall be 12 inches long,

plus the length required for winding on the mandrel. The specimen shall be
subjected to the specified temperature (see 3.1) for the following duration of
testing:

.,.,
. ..

Downloaded from http://www.everyspec.com

MIL-W-16878F{NAVY)

(a)
(b)

PE insulation
All (except PE, CSPE, EPDM)

(c) CSPE insulation

(d) EPDM insulation

48. plus 1. minus C)hours.

96, PIUS 1, minus O hours.

2k0, plus 1. minus O hours.
240, plus 1, minus O hours.

The specimen shall then be removed from the conditioning chamber and llowed to
return to room temperature. If strmd sealer has been used to make a watertight
construction, the sealing compound shall not drip from the ends of the wire. Me
length of exposed conductor, if any, at each end of the specimen shall be
considered as shrinkage of the Inaulaclon. In no case shall the shrinkage t
either end exceed 0.125 inch. Following the oven aging, nd unless otherwise
required in the applicable specification sheet, specimens shall be wound tightly
around a mandrel approximately (but not less than) three times the overall
diameter of the wire for five close turns and removed as helical coil. No
readily visible defects shall result from this heating and coiling. The coiled
sections shall be Immersed (except for approximately 2 inches t each nd) for 1
hour in tap wscer at room temperature, and shall then withstand the dielectric
withstanding voltage test specified in 4.5.3 for 1 minute. Wire shall meet the
requirements specified in 3.6.9.
L.s.11 ~
Testing for insulation flammability shall be as
performed in accordance with VW-1 flame test ethod of lJL Standard 1581. Wire
shall meet the requirements specified in 3.6.10.

6.5.12 ~.
8231 of FED-STD-228.

Finished vire shell be tested in ccordance with method

Insulation shall meet the requirements specified in 3.6.11.

inaocordance
4.5.13 ~.
The heat aging test shall be performed
with method 4031 of FED-sTD-228 with the following..exceptions:

(a) Temperature shall be as specified (see 3.1).

shall be 96, plus 1, minus O hours.
(b) Duration of hating
(c) Specimens shall be left at room tempera-e from 16 to 48 hours
before elongation and tensile strength tests are performed.
.
Insulation shall meet the requirements specified in 3.6.12.
The insulation tensile strength test
4=5-14 ~.
xcept that the
shall be performed in cco~e
W*
~~d
3021 of ~-~-228,
rate of travel of pmrer cwted
grip
shall be 2 inches (mimimum) amd20imchea
maxima) per minute travel. Insulation shall meet the requirements specified in
$.6.13.
The longation test shall be ~xfommed in
4*5*15 ~*
accordance with method 3031 of ~.STD-228,
except that the rate of travel Of
power actuated grip shall be 2 inches (minimum) and20 inches (maximum) per minute
treve1. Insulation shall meet the requirements specified in 3.6.14.
4.5.16
and stri~e durabilitv. ?%1s test shall determine the ability
of printed information on insulating or jacketing meteria]. to remain legible in

the presence of repeated abrasion.

21

Downloaded from http://www.everyspec.com

L. 5.16.1 $neclme~. The specimen shall consist of a piece of completed wire

which shall have suffieienr Aength for use in the test as specified in f+.S.16.3.
This test shall not apply to constructions which have clear jackets or braid over

the primary insulation.

Apparatus shall hcl@s
an bradin~machhe
4.5.16-2 ~.
which shall support and secure the specimen so that it is straight and horizontal,
and which shall abrade the specimen printed identification by means of a motor
driven. crmnsversely reciprocating steel pin. This steel pin shall have
diameter of 0.025 ~ 0.001 inch where it brades the specimen, and shall have a
surfaco roughness of not less than 2 aicroinches, in ccordance with ARSI B66.1.
(A selected sewing needle DSy satisfy these requirements.) The steel pin shall be
horizontal and perpendicular to the specimen axis, shall ride along ~Ae top of the
specimen, and shall be weighted to bear down on the specimen with a force of 1
plus 1/16, minb O pound for wire size number 24 or larger, and 1/2 plus 1/8,
minus O pound for wire size number 20 or less, at all times during the test. This
pin shall be reciprocatedat a rate of 60 ~ 2 cycles per minute, so that the pin
is drawn long the specimen for a distance of 3/8 plus 1/16, minus O inch in each
direction (3/4-inch minimum total excursion) during ach cycle. The abrading
machine shall incorporate an automatic counter to total the number of times that
the specimen is abraded by the steel pin during the test.
k.5.16.3 R ocedur~. The specimen shall be wiped with a clean, dry cloth to
remove any lubricant or dirt, and shall be secured in the abrading machine with
the specimen printed identification facing upwards, where it is co be abraded by
the steel pin. The automatic counter shall be set initially to zero. The
brading machine motor shall then be turned on, allowing the steel pin to
rec%procmte and abrade the specimen printed ideatlflcation either until the
printed identification is no longer Itgible in &e ibraded region, or until not
have been completed, whicheveroccurs
less than 125 abrasive cycles (250 strokes)
first. The number of abrasive cycles completed shall then be noted. This test
times COCS1), subjecting fresh
shall next be repeated four more times (five
portion of the specimen printed identlficacf.onco abrasion each time.

4
:..

i!%

4.5.16.4 Obsevatl~.
Specimen failure shall be const-ed if the median
value of the number of abrasive cycles co~leted during ach of the five tests is
less than 125.
k.s.17
r sisu~
The fungus resistance test shall be performed in
accordance with ASTM ; 21. Ui~e shall meet tho requirements specified in 3.6.16.
4.5.18 ~.
Toxiciv concentration levels for the finishedwire shall
not mxceed the values specified in ML-E-.917, table 1, in ccordance with the
methods apecl.fied(see 6.4). Wixo shall meat tk requirements specified in 3.9.

4.5.19
~lon
~.
This test Esthod measures the elongation of thin lug ofluire
insul~tion in the circumferential (radial) direction. The wire insulationslug is
radially elongated by axial movement of a capered cone through the stationary
s lug. Tho werall
test apparatus is shown in figure 2. A 1 to l-1/2-inchslug of
..
insulation shall be removed from the conductor. Care shall be taken to prevent ./;
.
1
~J

Downloaded from http://www.everyspec.com

HZ L-W-16878F(N.%:JY)

+-

.OIO-MAX.

~1

fmz~
EK)NGA

(SEEnGmE

29)

A17ACt+MEW

ME-

FOR BASEOF

r
!-

-.

I
I
TEST APIWUii

B
1
-1
L -------FIG 2A. TEsTMAMmELmR

cmtnwmmnu

-ATl~

CKXMFERENTIAL ELONGATIONTEST AFPARA~

? ?J

Downloaded from http://www.everyspec.com

~c~atchir.g,crirr~lng
srretc}lirg or otherkise damaging the insulation. me
diameter of the exposed conductor should be measured to the nearest 0.001 inch.
Cut five test specimens 0,125 inch ~.02 inch in length from the insulation slug
using A sharp razor blade or an appropriate sample preparation fixture. Both ends
of the cesr specimens shall becut square, Slide a specimen onto the cone until
it just touches the edges of che cone. The cone should be attached to.a moveable
crosshead as shown in figure 2a. Position the specimen holding block
perpendicular to the cone as shown in figure 2b. Align the cone tip and the
appropriate sized hole of che specimen holding block for the wire size being
tested. Move the cone through the stationary specimen at uniform speed of 20
k.2 inches/minuteuntil the specimen ruptures. Determine the length of the cone
that has passed through the specimen causing rupmre. The percent circumferential
elongation (% CE) is calculated as follows:
(2 x J.x Tan@ - CO~
%CE-

CD

x loot

L- Cone length required :0 rupture specimen (inches)

CD - Conductor diameter (inches)
# - Measured cone angle taper (degrees)
2 x L x Tan@ - Inner diameter of the test specimen at rupture (inches)
Five specimens shall be tested and the average value of the five specimens
calculated.

4.5.20 partial disa

le l test .Sample.of completed Insulatec
(Corq@
level specified in ASTllD
wire shall comply with the minimum dischar~e (coro&)
with the procedures of ICEA Publication T-24-380.
2802 when tested in accortince
4.6 Zn snection of
Sample
packages and packs, and the inspection
of the presentation, packing and marking for shipment and storage shall be in
accordance with the requirements of section 5 and the documents specified therein.
5.

PACKAGING

(The packaging requirements specified hdrein apply only for direct Government
acquisition. For the extent of applicability of the packaging requirementsof
referenced documents listed in section 2, see 6.5.)
. .
5.1 Gene*.
5.1.1 put-urn. Unless otherwise spmcifiod (see 3.1 end 6.2), the wire shall
be furnished in continuous lengths of 500 to 1000 feet coiled, on spools or reels t the contractors option. HO more than 25 percent of the total fooqge
of q
one wire part or identifyingnumber (PIN) (see 6.7) shall he shipped in lengths
less than minimum. See appendix B for PTFE length requirements.
5.2
e reuuirementq. The packaging of
5.1.1), shall be in accordance with tIIIL-C-12000for
or C), the level of packing (A, B, or Cj, including
acquisitioning options therein, as specified (see 6

2Ll

wire, put-up as specified (see

che level of preservation (A
marking and packaging
2). ln addition, for Navy

Ii!!

Downloaded from http://www.everyspec.com

zcquisi:ions

fol~owing applies:
Pam ffre .retardant re~uiremenc s.

tkke

(a)

r and D1vwood . ken specified (see 6.2), all lumber and

(1) J.umbe
plywood including laminated veneer material used in shipping
container
and pallet construction, menbers, blocking,
bracing, and reinforcing shall be fire-retardant treated
material conforming to MXL-L-19140 as follows:

Level A

Level C

nd

B - Type 11 wmather resistant.

Category 1 - general use.
. Type I non weather resistant.
Categorv 1 - general use.

~iberboard. Vhen spticified (see 6.2), fiberboard used in the

construction of class-domestic, non-weather resistant
fiberboard and cleated fiberboard boxes including interior

(2)

packaging forms shall meet che flame spread index and

specific optic density requirements of PPP-F-320 and
, amendments chereco.
. Unless ochemise specified (see 6.2), each coil
(b) ~ial~
spool or reel, as applicable, in addftion to the MIL-C-12000
marking requirements, shall be marked wi.chthe following:

[:; ~Ncification sheet title and date.

.
(3) !fanufacturers name or logo.
(4) Bar code.
6.

NOTES

(This section contains information of a general

may be helpful, but is not mandatory.)

or

explanatory nature that

6.1
ended USQ. The single conductor wire covered h th~s specification
1s intended for use in lead wire and internal wiring of electrical and electronic
equipment and switchboards.
6.1.1 ~ulatioq.
Precautionary considerations should be given
whexasolocting thin wall insulated wire. Wire having thin wall insulation of
0.007 inch thickness or less 1s intended for limited low voltage pplications. is asily damaged, and should not be used where mechanical stress
relatively frag{la,
or abrasive nvironment nay exist. Use of this wire may not be ppropriate in
circuits requiring the highest degree of reliability. In order to appear
consistent, the temperature rating is the same as assigned to heavier walls of the
same dielectric material. However, care should be taken during installation to
iron
or mechanical abuse and to
avoid damaging zhe dielectric wi:h hot Solderirtg
ieave no residual physical strain
cm the dielectric wall, because plastic flow may
result in failures.

Downloaded from http://www.everyspec.com

F!I1..
L-16U7W(NA1T)

zize desirnat icms . The conduc:or sfzes and the

6.i.2 ~Lrsndec? ccxk:c:
corresponding size designations of this specification re in accortincewith
established usage for stranded. copper conductors for hookup wire in the
electronic and aircraft industries. These Eizes and size designationsare not
identical with AWG sfzes for solid wire and stranded wire. The diameter and
cross-sectional areas of ~he stranded conductors of this specification are, in
most sizes, only roughly approximate to those of AWG solid conductors of the same
numerical size designation.
$alid conductc~.
The use of solid conductors should be cautioned.
Usage should be limited to lengths less than 10 inches and is not recommended
where flexing may occur or the wire may be subjected to different vibratory modes
along its length, such as between different chassis.
6.1.2

6.2 Acau~ion
following:
(a)
(b)
(c)

(d)
(e)
(f)
(g)
(h)
(i)

reauiremencs.

Acquisition documents UIUSCspecify the

Title, number. and date of this specification.

Classification of wire required (see 1.2 and 6.7).
Issue of DoDISS to be cited in the solicitation, and if required,
the specific issue of Indlvidud documencs referenced (see 2.1.1
and 2.2).
Title, number and date of applicable specification sheet (see 3-1).
Conductor coating matarial (see 3.4.1.1 through 3.4.1.7).
Whether braid, if required, is co be made of synthetic textile or
glass yarn (see 3.L.3).
Method of stranding for AUG sizes No. 10 and smaller, if ocher than
specified (see 3.5.1).
Product identification requirements, if other than specified
(see 3.7).

Quality conformance inspection lot, if other than specified

(m)

(see 4.L.1).
Length of wire, if other than specified (see 5.1.1).
Form or put-up if other than contractors option (see 5.1.1).
Coil, spool, and reel marking requirements, if ocher than specified
(see 5.2 and 5.2(b)).
Leve2 of preservation, packing, nd packaging opciona required

(n)
(o)

(see 5.2).
Fire-retardant material, when required (see 5.2(a)).
or time conditions.
Special or unique storage

(j)
(k)
(1)

6.3 ~.
When first article inspection 1s required, the
contracting officer
should provide specific guidance to offerors whether tie
item(s) should be preproduccion sample, a first article sample, a first
production item, a sample selected from the first 10 production items, a standard
current inventory (3.2), ~
tie ber
production item from the contractors
of items to be tested as spec$fled in 4.3. The contracting officer
should lso
inchde specific instructions in acquisition documents regarding arrangementsfor
examinations, approval of first arricle test results, and disposition of first
articles. Invitations for bids should provide that the Government resenes the
right to waive the requirement for samples for firs= article inspection to those ....
PIEJiOUSl-J
acquired rIrreseed by the
bidders offeri!l~ z IIrcduc:Khick tI~S k)~erl

Downloaded from http://www.everyspec.com

tlXL-U-16878F(NAVy)

Government, and that bidders offering such products. who wish to reiV on such
production or test, must furnish evidence with the bid that prior Government

approval is presently appropriate for the pending contract. Bidders should not
unless specifically requested to do so in the solicitation.

submit alternate bi&

6.&
T~~~=if-v
~ ~ticm
respect to
Wi@
lev~
of
toxicity levels of wire inspected to this specification, it is the Governments
intent to accumulate data from the testing of first rticle samples. Ikis data
will be compiled and evaluated to establish appropriate concentration levels of
toxic gases for future acceptable maximum concentration levels. Contractors are
requested to provide such data with respect to their products following first
article testing. This data will not be used for the rejection of my product
first article testing.

6.5
$ub-cont~ted
material and Dartsi. The packaging requirements of
referenced documents listed in section 2 do not apply when material and parts are
acquired by the contractor for incorporation into the equipment and lose their

separate identity when the equipment is shipped.

6.6

Mt

6.6.1

acce~ta.mk.md

rejection

criteria.

Grouv A i.nsoection.

. Failure of
6.6.1.1 Visual and mechanical exafmination(exceDt for s~
any sample to pass these examinations constitutes a failure of the lot (see
L.Z.3.1:1).
6.6.2

B ~.

f&uD

The acceptance quality level (AQL)

6.5

percent.
6.6.2.1 Jloncomliunce. If a sample fails to pass group B inspection, the
contractor should notify the cognizant inspection activity of such failure and
take corrective action on the materials or processes, or both, as warranted, and
on all units of the product which can be coirected and which were manufactured
with essentially the same materials and processes, and which are co=idered
s~ject to the same failure. Acceptance and shipment of.the product will be
discontinued until corrective action acceptable to the inspection activity has
been taken. After the corrective action has been taken, group B inspection should
be repeated on dditional sample units. (~is includes ll tests and examinations, or the test which the original sample failed, t the option of the
inspection activi~.)
Croup A inspection may be reinstituted; however, final
acceptance and shipment will be witield until group B inspection has shown that
the corrective action wes successful. In the event of failure after reinspection, information concerning the failure should be provided to the cognizant inspection
activity.
6:7

~.

PINs should be of the following form, as specified (see 6.2):

~878/lJ
(see 6.7.1)

II
(see 1.2.3)

G
(see 1.2.4)

?7

E
(see 1.2.5)

*
(see 1.2.6)

w?

Downloaded from http://www.everyspec.com

6.7.1 !jilIrarw soecjfication st~eetn~ber.

The ?l:litary specificat~on sheet
number designation consiscs of a prefix H which indicates an item defined by inchpound units, the specification number, and the specification sheet number followed
by applicable dash numbers (letters).
6.8

$xbiect term (V.evword) listil!g.

Chlorosulfonated polyethylene
Conductor, solid
Conductor, stranded
Ethylene-propylene diene lastomer
Polyolefln, cross-linked
Polyamide
Polyethylene
Polytetrafluoroethylene
Pol~inyl chloride
Rubber, silicone

6.9 Chan~es from Drevious issq.

?larginal nocacions are not used in this
revision to identify changes with respect to the previous issue due to the
extensiveness of the changes.

Reviewing activity:
Navy

- AS

Preparing activicy:

Navy - SH
(Project 6145-N330)

Downloaded from http://www.everyspec.com

A?PESl)::iP.
~IRE,

E~cTRIc*L,

lNsu~~EJ)

GENEIUL SPECIFICATION FOR

.
10.

SCOPE

10.1 ~COD~.
This ppendix provides a guide for supersession of wire types
defined in MIL-U-16878D to those covered in HIL-U-16878F.

20. APPLICABLE DOCUMENTS

This section is not applicable to this appendtx.

30. SUPERSESSION DATA

!?IL-N-15876D
GENERAL DESCR1PTION

MIL -W-16878~

MlL-U-16878F

M16878/1

M16878/17

M16878/1
K16878/17

1000 VOLT, 105C PVC

TYPE C
H16878/18

?i16t378/2
t416878/18

H16878/2

VOLT, 105-C PVC

TYPE D
H16878/19

M16878/3
K16878/19

H16878/3

TYPE E

H16878/4
tt16878/21
H16878/25
!416878/26

M16878/4
U16878/21

M16878/5
!06878/22
tf16878/27
!416878/28
U16878/34
H16878/35

M16878/5
H16878/22

X1687816
U16878/20
CS16878/23
M16878/24

K16878/6
!416878/20

600 VOLT, 105*C PVC

3000

600 VOLT, 200-C/260*C

TYPE B

Pm
M16878/25
!516878/26

1000 VOLT, 200*C/260-C

PTFE

TYPE EE
ri16878/27
M16878/28
!416878/34
M16878/35

250 VOLT, 200C/260*C

PTFE

TYPE ET
M16878/23
M16878/24

,,

Downloaded from http://www.everyspec.com

P!l L.u-16878F(NAm-)

GENERAL DESCRIPTION

600 VOLT, SILICONE

TYPE F

K16878/7
K16878/29

316878/7
M16878/29

TYPE FF

H16878/8
!i16878/30

!116878131
M16878/32

H16878/8
H16878/30
!f16878/31
M16876/32

PE, 75-C

TYPE J
M16878/33

K16878/10
U16878/33

M16878/10

FEP, 600 VOLT, 200C

TYPE X

M16878/11

H1687B/11

PEP. 1000 VOLT, 200C

TYPE I(X

H16878/12

M16878/12

FEP, 250 VOLT, 200D

TYPE XT

M16878/13

M16878/13

RUBBER
1000 VOLT, SILICONE
RUBBER

XLPE, 600 VOLT, 125C

---

-.-.-

M16878/14

XLPE, 1000 VOLT, 125*C

.-.

--..-

11116878/15

XLPE, 3000 VOLT, 125=C

---

-----

K16878/16

XLPO, 600 VOLT, 105*C

---

-.-.-

F$16878/36

EPDH, 600 VOLT, 150C

-..

-----

H16878/37

EPDH, 5000 VOLT, 125-C

---

-----

M16878/38

___
{ . .

{f

Downloaded from http://www.everyspec.com

10.

SCOPE

This appendix establishes the minimum continuous wire lengths

10.1 scoDe.
The information
contained
for ~olvtetrafluorethylene (=FE) wire constructions.
herek is intended for compliance unless there is an alternative specified in 6.2.

20. APPLICABLE DOCUMENTS

Thi6 section is not applicable to this appendix.
30. REQuxREMEIWs
30.1 W . UQ Tabu~at ion. Due to the nature of the PTFE wire-forming process,
and quantity of pieces per spool or reel
Table B1 suecifips the minimum lengths
that

re

acceptable unless otherwise specified. ~see 6.2)

TABLE B1.

AWG size

Pur -up ciibulacion for PTFP.wire construct ims .

Percentage of

or&r

32

to

22

20 to 16

Length (feet)
one continuous
length

Max. no. of lengths (per spool

or reel)

500-1000 ft.

1001-1500 ft.

50 - 75
75 - 300
301 or more

25
50
Unacceptable

Under 75

25

20
50
30

75 - 100
101 - 300
301 or mora

14 to 10

Unacceptable
40
.
50
10

Under 50
50 - 100
101 - 300
301 - more

8 and larger

10
70
20

25 - 50
50 - 100
100 or more

30.2 ~
Pla~.
Each spool or reel shall be marked accordingly with
the length in feet and location of each piece.

,,

.,---

Downloaded from http://www.everyspec.com

Downloaded from http://www.everyspec.com

STANDARDIumON DOCUMENT

PROPOSAL

IMPROVEMEW

INSTRUCTIONS
1.

The preparing activity mu$t tomplete blocks 1, 2, 3, and 8.

letter
should be given.

2.

The submitter of this form must complete blocks 4,5,6,

In block 1, both the document

number

and revision

and 7.

3.

The preparingactivity must provide a reply within 30 days from receipt of the form.
nor to request wti-,
or clarification
NOTE: This form may not be wed to request copies of documenti,
Comments
submitted
on
this
form
do
not
constitute
or
imply

. uthofiutiw
requirement
on current contracts.
waive any portion of the referenced document(s) or to
mend contractual requirement.
X 00WMEMT OATt (~-)

of
to

11 SEPTEMBER 1992

WIRE , ELECTRICAL,
. NATURE W --GE
(titifY

_.. .- . . ...-
. NAME

INSULATED. GENERAL SPE

PwWWh

t.

Y.

~~*

~wbk.

A~~

b.

(703)

SEA 05E23

LU.,

AOORESS
@CludP
z code

COMMAM)ER
, ATT ~:

(!5Q42,

NAVU

89

Previous

-~

~~

602-3124

Ama

-J

(2) Mnc7vcm
8-332-3124

F YOU DO NOT RECEIVE A REMY WKNIN 45 DAYS. CONYACT:

oetwne OualitYWI Standardizatm Otke
S203 MSbUKj
P[ke. $Wte ~403,FBIIsChub, VA 22041
.Mti
AuToWN 28%23@
~der)twe(703)7%-z3~

SEA SYSTDfS

COMMAND , 2531 NATIONAL CENTER 3

WASHIN~ON , I).
C . 20362-5160
-,--L__
cM3 Form 1426, OU

TaEPMq4E (-

{1)Commerf-1

OF CONTRACT

~~

~-r

rv

TECHNICAL POUT
MR. C.

-br

ditlon.f

@r@

ObSO&@

.:. :